2S6-F8197-E0_ cover 05.11.

21 1:45 PM Page 1

T135HC

SUPPLEMENTARY
SERVICE MANUAL

2S6-F8197-E0
2S6-7-E0-01 05.11.18 1:13 PM Page a1

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
T135HC. For complete service information procedures it is necessary to use this Supplementary
Service manual together with the following manual.

T135SE SERVICE MANUAL: 1S7-F8197-E0

EAS00000

T135HC
SUPPLEMENTARY
SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
First edition, November, 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
2S6-7-E0-01 05.11.18 1:13 PM Page a2

EAS00002

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.

NOTE:
Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!

w Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

cC A CAUTION indicates special precautions that must be taken to avoid damage

to the vehicle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

2S6-7-E0-01 05.11.18 1:13 PM Page a3

EASF0001

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1:This is a chapter with its symbol on the upper right of each page.
2nd title 2:This title appears on the upper of each page on the left of the chapter symbol. (For the
chapter “Periodic inspection and adjustment” the 3 rd title appears.)
3rd title 3:This is a final title.

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step - by - step format. The informa-
tion has been compiled to provide the mechanic with a easy to read, handy reference that contains com-
prehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of mark “▼” or “▲” with each pro-
cedure preceded by “8”.

IMPORTANT FEATURES
8Data and a special tool are framed in a box preceded by a relevant symbol 5 .
8An encircled numeral 6 indicates a part name, and an encircled alphabetical letter date or an align-
ment mark 7, the others being indicated by an alphabetical letter in a box 8 .
8A condition of a faulty component will precede an arrow symbol and the course of action required the
symbol 9 .

EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
2S6-7-E0-01 05.11.18 1:13 PM Page a4

1 2 SYMBOLS
The following symbols are not relevant to every
GEN SPEC vehicle.
INFO Symbols 1 to 9 indicate the subject of each
3 4 chapter.

1 General information
CHK ENG 2 Specifications
ADJ 3 Periodic checks and adjustments
4 Engine
5 6 5 Cooling system
6 Carburetor
7 Chassis
COOL CARB 8 Electrical system
9 Troubleshooting
7 8
Symbols 0 to u indicate the following.
CHAS ELEC 0 Serviceable with engine mounted
q Filling fluid
9 0 w Lubricant
e Special tool
TRBL r Tightening torque
t Wear limit, clearance
SHTG y Engine speed
u Electrical data
q w
Symbols i to d in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
e r
i Engine oil
o Gear oil
p Molybdenum-disulfide oil
a Wheel-bearing grease
s Lithium-soap-based grease
t y u d Molybdenum-disulfide grease

Symbols f to g in the exploded diagrams indi-

cate the following.
i o p
f Apply locking agent (LOCTITE®)
g Replace the part

a s d

f g

LT New
2S6-7-E0-01 05.11.18 1:13 PM Page a5

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS ……………………………………………… 1
MAINTENANCE SPECIFICATIONS ……………………………………… 2
ENGINE …………………………………………………………………… 2
CHASSIS ………………………………………………………………… 3
CABLE ROUTING …………………………………………………………… 4

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION……………………………………………………………… 8
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ……… 8
ENGINE ……………………………………………………………………… 10
ADJUSTING THE CLUTCH CABLE FREE PLAY …………………… 10

ENGINE
REMOVING THE ENGINE ………………………………………………… 12
WIRE, CABLE AND HOSE ……………………………………………… 12
INSTALLING THE ENGINE ………………………………………………… 12
WIRE, CABLE AND HOSE ……………………………………………… 12
CLUTCH ……………………………………………………………………… 13
REMOVING THE CLUTCH ……………………………………………… 14
CHECKING THE CLUTCH PUSH RODS……………………………… 16
INSTALLING THE CLUTCH …………………………………………… 16
SHIFT SHAFT ………………………………………………………………… 20
KICKSTARTER ……………………………………………………………… 21
REMOVING THE KICKSTARTER ……………………………………… 21

CHASSIS
FRONT WHEEL AND BRAKE DISC ……………………………………… 23
REAR WHEEL AND BRAKE ……………………………………………… 24
HANDLEBAR ………………………………………………………………… 25
REMOVING THE HANDLEBAR………………………………………… 26
INSTALLING THE HANDLEBAR ……………………………………… 28
2S6-7-E0-01 05.11.18 1:13 PM Page 1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model T135HC
Model code 2S61
Weight
Wet (with oil and full fuel tank) 112 kg (247 lb)
Oil type or grade
Engine oil SAE 20W40 type SF, SG or higher grade
motor oil/JASO MA
Periodic oil change amount 0.8 L (0.70 Imp.qt, 0.85 US qt)
Total amount 1.15 L (1.01 Imp.qt, 1.22 US qt)
Fuel
Recommended fuel Regular unleaded gasoline
Fuel tank capacity 4.0 L (0.88 Imp.gal, 1.06 US gal)
Clutch type Wet, multiple-disc
Tire
Type With tube
Size front 70/90-17M/C 38P
rear 80/90-17M/C 44P
Model (manufacturer) front DUNLOP/D102FA
rear DUNLOP/D102A
Min. tire tread depth front 0.8 mm (0.03 in)
rear 0.8 mm (0.03 in)

–1–
2S6-7-E0-01 05.11.18 1:13 PM Page 2

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Clutch
Friction plate #1
Thickness 2.5 – 2.7 mm (0.10 – 0.11 in) 2.4 mm
(0.09 in)
Plate quantity 3 ----
Friction plate #2
Thickness 2.5 – 2.7 mm (0.10 – 0.11 in) 2.4 mm
(0.09 in)
Plate quantity 1 ----
Clutch plates
Thickness 1.59 – 1.68 mm (0.06 – 0.07 in) ----
Plate quantity 3 ----
Max. warpage ---- 0.05 mm
(0.0020 in)
Clutch springs
Free length 40.5 mm (1.60 in) 38.5 mm
(1.52 in)
Spring quantity 4 ----
Clutch release method Outer pull, cam pull ----
Clutch cable free play 8 – 12 mm (0.37 – 0.47 in) ----
(at end of the clutch lever)
Shifting mechanism
Shift mechanism type Shift drum and guide bar ----
Shift fork thickness 4.76 – 4.89 mm (0.1874 – 0.1925 in) ----
Carburetor
Type VM22 ----
I.D. mark 2S61 01 ----
Main jet (M.J) #103, 8 ----
Main air jet (M.A.J) ø1.2 ----
Jet needle (J.N) 5K010 ----
Needle jet (N.J) N-9M ----
Pilot outlet (P.O) ø1 ----
Pilot jet (P.J) #20 ----
Pilot air screw turns out 1-5/8 ----
Pilot air jet 1 #55 ----
Valve seat size ø2 ----
Throttle valve size #2.0 ----
Float height 9.2 mm (0.3622 in) ----

–2–
2S6-7-E0-01 05.11.18 1:13 PM Page 3

MAINTENANCE SPECIFICATIONS SPEC

CHASSIS
Item Standard Limit
Front wheel
Wheel type cast
Rim size 17 × 1.40 ----
Rim material Aluminum ----
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 0.5 mm
(0.02 in)
Rear wheel
Wheel type cast
Rim size 17 × 1.60 ----
Rim material Aluminum ----
Max. radial wheel runout ---- 1.0 mm
(0.04 in)
Max. lateral wheel runout ---- 0.5 mm
(0.02 in)
Drive chain
Type/manufacturer 428/PT. FSCM ----
Link quantity 112 ----
Drive chain slack 25 – 35 mm (0.98 – 1.38 in) ----

–3–
2S6-7-E0-01 05.11.18 1:13 PM Page 4

CABLE ROUTING SPEC

CABLE ROUTING
1 Turn signal light relay å Install the turn signal relay onto ∂ Connect the couplers in front of
2 Meter assembly the bracket. the handlebar left side once
3 Left handlebar switch lead ∫ Pass through the left handlebar and behind the other one.
4 Speedometer cable switch lead coupler behind the ´ Do not pass the brake hose
5 Wireharness handlebar left, and then con- into the bracket.
6 Brake hose nect them. Take care to pinch ƒ Pass through into the wire
7 Throttle cable the coupler between the guide, follow the routing order.
8 Front brake light switch lead speedometer assembly and Throttle cable, wireharness
9 Clutch cable handlebar. and brake hose.
ç Pass through the choke cable
into the wire guide.

1 å 2 ∫ ç 3

8
ˆ ˙ C
∆ 9 ˚
C
∂
7
4
6
5
´

7 ƒ
6
5
4 ©
9
A-A
6 7
5
4 D

9 A
B
B-B A

9 D

–4–
2S6-7-E0-01 05.11.18 1:13 PM Page 5

CABLE ROUTING SPEC

© Hook the strap of the wirehar- ∆ Route the right handlebar
ness onto the turn signal light switch lead behind the handle-
relay bracket. bar and connect the coupler
˙ Pass through the brake hose with handlebar right side, and
into the wire guide on the han- then set the turn signal light
dlebar bracket. relay.
ˆ Pass the wireharness behind ˚ Take care not to bend the
the turn signal relay and brake choke cable when installing.
hose, and then connect the
front brake light switch.

1 å 2 ∫ ç 3

8
ˆ ˙ C
∆ 9 ˚
C
∂
7
4
6
5
´

7 ƒ
6
5
4 ©
9
A-A
6 7
5
4 D

9 A
B
B-B A

9 D

–5–
2S6-7-E0-01 05.11.18 1:13 PM Page 6

CABLE ROUTING SPEC

1 Throttle position sensor lead e Overflow pipe ∂ Pass through the wireharness
2 Radiator inlet hose r Wireharness into the main switch and cable
3 Grommet t Clutch cable guide.
4 Plate Pass through the hone lead
5 Fan motor lead å Turn the downward of the sep- and turn signal light lead under
6 High tension cord arate part. the wireharness.
7 Main switch lead ∫ Route the brake hose through ´ Route the brake hose as
8 Horn lead as shown. shown.
9 Thermo switch lead ç Clamp the wireharness only. ƒ Clamp the bend hose.
0 Bend hose Wireharness and cable guide © To the neutral switch.
q Fuel hose clearance is wit in 16 mm, ˙ Turn the clip inside without
w Vacuum hose when straight the steering con- contact the vacuum hose.
dition.

q w e © ˙ ˆ

∫
B
C 8
7
6 ç
5
å t
4 B
3
1 2 ∂
˚
´
M

C
AX

r
5

µ
CU
T

A A-A
t

0
˜ ƒ

–6–
2S6-7-E0-01 05.11.18 1:13 PM Page 7

CABLE ROUTING SPEC

ˆ To the A.C. magneto. µ Pass through the clutch cable.
∆ Cover the protector completely, ˜ Route the clutch cable to inside
after the coupler connected. of the wireharness and outside
˚ Set the connected point below of the engine bracket.
the pipe end.
¬ Pass through the high tension
cord, fan motor lead and ther-
mo sensor lead into the cut part
on the plate.

q w e © ˙ ˆ

∫
B
C 8
7
6 ç
5
å t
4 B
3
1 2 ∂
˚
´
M

C
AX

r
5

µ
CU
T

A A-A
t

0
˜ ƒ

–7–
2S6-7-E0-01 05.11.18 1:13 PM Page 8

INTRODUCTION/ CHK
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ADJ
EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If fol-
lowed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer
service life and reduce the need for costly overhaul work. This information applies to vehicles already in
service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAS00037

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

ODOMETER READING (× 1000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24 CHECK

1 * Fuel line 9 Check fuel and vacuum hoses for cracks or damage. √ √ √ √ √
9 Check condition.
9 Clean and regap.
√ √
2 Spark plug
9 Replace. √ √
3 * Valves
9 Check valve clearance.
9 Adjust.
√ √ √ √
9 Clean. √ √
4 Air filter element
9 Replace. √ √
5 Clutch
9 Check operation.
9 Adjust √ √ √ √ √

6 * Battery
9 Check electrolyte level and specific gravity.
9 Make sure that the breather hose is properly routed.
√ √ √ √ √
9 Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √
7 * Front brake
9 Replace brake pads. Whenever worn to the limit
9 Check operation and adjust brake pedal free play. √ √ √ √ √ √
8 * Rear brake
9 Replace brake shoes. Whenever worn to the limit
9 Check for cracks or damage. √ √ √ √ √ √
9 * Brake hose
9 Replace. Every 4 years

10 * Wheels 9 Check runout and for damage. √ √ √ √

9 Check tread depth and for damage.
11 * Tires
9
9
Replace if necessary.
Check air pressure.
√ √ √ √ √
9 Correct if necessary.
12 * Wheel bearings 9 Check bearing for looseness or damage. √ √ √ √
9 Check operation and for excessive play. √ √ √ √
13 * Swingarm
9 Lubricate with lithium-soap-based grease. Every 24000 km
9 Check chain slack, alignment and condition. Every 500 km and after washing the motorcycle or
14 Drive chain
9 Adjust and thoroughly lubricate chain with engine oil. riding in the rain
9 Check bearing play and steering for roughness. √ √ √ √ √
15 * Steering bearings
9 Lubricate with lithium-soap-based grease. Every 24000 km

16 * Chassis fasteners
9 Make sure that all nuts, bolts and screws are properly
tightened.
√ √ √ √ √
17 Sidestand, centerstand
9 Check operation.
9 Lubricate.
√ √ √ √ √
18 * Front fork 9 Check operation and for oil leakage. √ √ √ √
19 *
Shock absorber assem-
bly
9 Check operation and shock absorber for oil leakage. √ √ √ √
20 * Carburetor
9 Check starter (choke) operation.
9 Adjust engine idling speed.
√ √ √ √ √ √
21 Engine oil
9 Change.
9 Check oil level and vehicle for oil leakage.
√ √ √ √ √ √
22 Engine oil filter element 9 Replace. √ √ √

–8–
2S6-7-E0-01 05.11.18 1:13 PM Page 9

CHK
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ADJ
ODOMETER READING (× 1000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24 CHECK

9 Check coolant level and vehicle for coolant leakage. √ √ √ √ √

23 * Cooling system
9 Change the YAMAHA GENUINE COOLANT. Every 3 years

24 *
Front and rear brake
switches
9 Check operation. √ √ √ √ √ √
25
Moving parts and ca-
bles
9 Lubricate. √ √ √ √ √
9 Check operation and free play.
26 *
Throttle grip housing
and cable
9 Adjust the throttle cable free play if necessary. √ √ √ √ √
9 Lubricate the throttle grip housing and cable.
9 Check the air cut-off valve, reed valve, and hose for dam-
27 * Air induction system age. √ √ √ √ √
9 Replace any damaged parts if necessary.

28 *
Lights, signals and
switches
9 Check operation.
9 Adjust headlight beam.
√ √ √ √ √ √
EAU18660

NOTE:
7 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
7 Hydraulic brake service
9 Regularly check and, if necessary, correct the brake fluid level.
9 Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
9 Replace the brake hoses every four years and if cracked or damaged.

–9–
2S6-7-E0-01 05.11.18 1:13 PM Page 10

CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY ADJ
EAS00049

a ENGINE
EAS00078

ADJUSTING THE CLUTCH CABLE

FREE PLAY
1. Check:
9 clutch cable free play a
Out of specification → Adjust.

Clutch cable free play (at the end

of the clutch lever)
8–12 mm (0.32–0.47 in)

2. Remove:
9 headlight assembly
Refer to “COVERS” in 1S7-F8197-E0
chapter 3.

3. Adjust:
9 clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction a
or b until the specified clutch cable free
play is obtained.

Clutch cable free play

Direction a
is increased.
Clutch cable free play
1 Direction b
is decreased.
b

c. Tighten the locknut.

a NOTE:
If the specified clutch cable free play cannot
2
be obtained on the handlebar side of the
cable, use the adjusting nut on the engine
side.

–10–
2S6-7-E0-01 05.11.18 1:13 PM Page 11

CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY ADJ
2 Engine side
b a. Loosen the locknuts 1.
b. Turn the adjusting bolt 2 in direction a
a
1 or b until the specified clutch cable free
play is obtained.

Clutch cable free play

Direction a
is increased.
Clutch cable free play
Direction b
is decreased.

c.Tighten the locknuts.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Install:
9 headlight assembly
Refer to “COVERS” in 1S7-F8197-E0
chapter 3.

–11–
2S6-7-E0-01 05.11.18 1:13 PM Page 12

REMOVING THE ENGINE/INSTALLING THE ENGINE ENG

EASF0018

ENGINE
REMOVING THE ENGINE
WIRE, CABLE AND HOSE
1. Disconnect:
9neutral switch lead coupler 1
9stator coil lead coupler 2
1
2 9pick up coil lead coupler 3
3
9crankcase breather pipe

2. Remove:
9spark plug cap

3. Disconnect:
9clutch cable 1 (engine side)
NOTE:
1 Loosen the locknut and slacken the clutch cable,
before disconnect.

4. Remove:
9fuel cock vacuum hose 1

5. Remove:
9crankcase breather pipe 1

EASF0019
1
INSTALLING THE ENGINE
WIRE, CABLE AND HOSE
1. Connect:
9neutral switch lead coupler
9pickup coil lead coupler
9stator coil lead coupler

2. Install:
9crankcase breather pipe
9fuel cock vacuum hose
9spark plug cap
9clutch cable

–12–
2S6-7-E0-01 05.11.18 1:13 PM Page 13

CLUTCH ENG
EASF0029

CLUTCH
1 Clutch pressure plate bolt 9 Circlip u Clutch boss nut
2 Clutch spring 0 Clutch push rod #2 i Clutch boss
3 Clutch pressure plate q Push lever o Clutch housing
4 Friction plate #1 w Spring p Primary drive gear nut
5 Clutch plate e Washer a Primary drive gear
6 Friction plate #2 r Crankcase cover (right) s Straight key
7 Cushion ring t Gasket d Flywheel assembly
8 Seat plate y Clutch push rod #1 f Spacer

q 9

w r
LS
e
0
12 Nm (1.2 m•kg, 9.0 ft•lb )

t
E

1 y
3
2
5
E

4 u

6
7
8

a 70 Nm (7.0 m•kg, 50 ft•lb )

i

p
d f
s o
E

50 Nm (5.0 m•kg, 36 ft•lb )

–13–
2S6-7-E0-01 05.11.18 1:13 PM Page 14

CLUTCH ENG
EAS00277

REMOVING THE CLUTCH

1. Drain:
9engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
1S7-F8197-E0 chapter 3.
2. Remove:
9side cowlings (left and right)
Refer to “REMOVING THE SIDE COWL-
INGS” in 1S7-F8197-E0 chapter 3.
9muffler
9footrest
9brake pedal
Refer to “REMOVING THE ENGINE” in
1S7-F8197-E0 chapter 4.
9kickstarter lever
Refer to “KICKSTARTER”.
9crankcase cover (left)
Refer to “GENERATOR”.
3. Remove:
9clutch cable 1
9circlip 2
9push lever 3
3 9spring 4
9washer

1
2
4 4. Remove:
9crankcase cover (right)
5. Remove:
1 9clutch pressure plate bolts 1
9clutch springs
9clutch pressure plate 2
9clutch push rod #1
NOTE:
1 Loosen each bolt 1/4 of a turn at a time, in
2
stages and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.

6. Remove:
3 9friction plates #1 1
4
9friction plates #2 2
9clutch plate 3
9cushion ring 4
9seat plate 5
1
2 5

–14–
2S6-7-E0-01 05.11.18 1:13 PM Page 15

CLUTCH ENG
7. Straighten the lock washer tab.
3
8. Loosen:
2
9clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the univer-
sal clutch holder 3, loosen the clutch boss nut.

1 Universal clutch holder

90890-04086

9. Remove:
9clutch boss nut 1
5 9lock washer 2
1 6 9clutch boss 3
9washer 4
2
9clutch housing 5
3 9spacer 6
4

10. Remove:
9primary drive gear nut 1
9washer
NOTE:
9Loosen the primary drive gear nut while holding
1 the generator rotor 2 with the sheave holder
3.
9Do not allow the sheave holder to touch the
projection on the generator rotor.

Sheave holder
90890-01701
2

–15–
2S6-7-E0-01 05.11.18 1:13 PM Page 16

CLUTCH ENG
11. Remove:
1
9primary drive gear 1
3 9flywheel 2
9straight key 3
9spacer

CHECKING THE CLUTCH PUSH RODS

2 1. Check:
9clutch push rod #1 1
Cracks/damage/wear → Replace the clutch
1 push rod #1.
9clutch push rod #2 2
Cracks/damage/wear → Replace the clutch
push rod #2.

2. Check:
9push lever assembly
Cracks/damage/wear → Replace the push
lever assembly.

EAS00293

INSTALLING THE CLUTCH

1 3 1. Install:
9spacer
9straight key 1
9flywheel 2
9primary drive gear 3
9washer
2
9primary drive gear nut

–16–
2S6-7-E0-01 05.11.18 1:13 PM Page 17

CLUTCH ENG
2. Tighten:
9primary drive gear nut 1
50 Nm (5.0 m•kg, 30 ft•lb)
NOTE:
9While holding the generator rotor 2 with the
1 sheave holder 3, tighten the primary drive gear
nut.
9Do not allow the sheave holder to touch the
projection on the generator rotor.

Sheave holder
90890-01701
2

4 3. Install:
2 9spacer 1
6 1 9clutch housing 2
5 9washer 3
9clutch boss 4
3 9lock washer 5
3
9clutch boss nut 6
NOTE:
Face the press dropped side toward the clutch
housing, and then install the washer 3.
3
2 4. Tighten:
9clutch boss nut 1
70 Nm (7.0 m•kg, 50 ft•lb)
NOTE:
While holding the clutch boss 2 with the univer-
sal clutch holder 3, tighten the clutch boss nut.
1
Universal clutch holder
90890-04086

–17–
2S6-7-E0-01 05.11.18 1:13 PM Page 18

CLUTCH ENG
5. Bend the lock washer tab along a flat side of
the nut.
6. Lubricate:
9seat plate
9cushion ring
9friction plates #1
9friction plate #2
9clutch plates
(with the recommended lubricant)

Recommended lubricant
4 5 Engine oil
3
7. Install:
9seat plate 1
1 9cushion ring 2
2 9friction plate #2 3
9clutch plates 4
9friction plates #1 5
NOTE:
9Make sure to face the cushion ring 2 toward
as shown illustration, and then install it onto
3
the clutch boss.
2 9First, install the seat plate, cushion ring and
then alternate between a clutch plate and a
friction plate.

3 8. Install:
9clutch push rod #1 1
1 9clutch pressure plate 2
9clutch springs
9clutch pressure plate bolts 3
12 Nm (1.2 m•kg, 9.0 ft•lb)
NOTE:
b
9Align the punch mark a on the pressure plate
with clutch housing mark b.
a 9Tighten the clutch pressure plate bolts in
stages and in a crisscross pattern.

9. Install:
9dowel pins
9gasket
1
9crankcase cover (right)
2 NOTE:
Set the clutch push rod #1 1 cut away part as
shown, and then align with the cut away and
claw of the clutch push rod #2 2 to install the
crankcase cover (right).

–18–
2S6-7-E0-01 05.11.18 1:14 PM Page 19

CLUTCH ENG
10. Tighten:
9crankcase cover bolts 1
10 Nm (1.0 m•kg, 7.2 ft•lb)

11. Install:
9oil level plug

12. Install:
9washer
9spring 1
9push lever 2
9circlip
3
NOTE:
Turn the push rod #2 3 clockwise until it stops,
and then align with the mark a and punch mark
2 b b and install the push lever 2.

1
13. Connect:
9clutch cable

14. Adjust:
9clutch cable free play
a
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY”.

–19–
2S6-7-E0-01 05.11.18 1:14 PM Page 20

SHIFT SHAFT ENG

EASF0032

SHIFT SHAFT
1 Shift pedal 8 Shift drum segment
2 Shift shaft
3 Shift lever assembly
4 Stopper lever spring
5 Stopper lever assembly
6 Collar
7 Plate

12 Nm (1.2 m•kg, 9.0 ft•lb )

7
8
10 Nm (1.0 m•kg, 7.2 ft•lb )
5

6
3

4
2
E

E 1

18 Nm (1.8 m•kg, 13 ft•lb )

–20–
2S6-7-E0-01 05.11.18 1:14 PM Page 21

KICKSTARTER ENG
KICKSTARTER
REMOVING THE KICKSTARTER
1. Drain:
9engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL” in
1S7-F8197-E0 chapter 3.
9coolant
(completely from the water jacket)
Refer to “CHANGING THE COOLANT” in
1S7-F8197-E0 chapter 3.

2. Remove:
9side cowlings (left and right)
9front cowling
9center panels (upper and lower)
9rear cowlings (left and right)
Refer to “COVERS” in 1S7-F8197-E0 chap-
ter 3.
9carburetor assembly
Refer to “CARBURETOR” in 1S7-F8197-E0
chapter 6.
9muffler
9footrest
9Brake pedal
Refer to “REMOVING THE ENGINE” in 1S7-
F8197-E0 chapter 5.

3. Remove:
9cylinder head
Refer to “CYLINDER HEAD”.
9cylinder
9piston
Refer to “CYLINDER AND PISTON”.
4. Disconnect:
2 3 9clutch cable

5. Remove:
1 9kickstarter nut 1
9kickstarter lever 2

6. Remove:
9oil level plug
9crankcase cover bolts
9crankcase cover (right) 3
9gasket
9dowel pins
NOTE:
Be sure to remove the oil level plug first when
remove the crankcase (right).
–21–
2S6-7-E0-01 05.11.18 1:14 PM Page 22

KICKSTARTER ENG
7. Remove:
9clutch
Refer to “CLUTCH” in 1S7-F8197-E0 chap-
ter 5.
9shift shaft
Refer to “SHIFT SHAFT” in 1S7-F8197-E0
chapter 5.
9oil pump assembly
Refer to “OIL PUMP” in 1S7-F8197-E0
chapter 5.
9generator
Refer to “GENERATOR AND STARTER
CLUTCH” in 1S7-F8197-E0 chapter 5.

8. Remove:
9engine
Refer to “REMOVING THE ENGINE” in 1S7-
F8197-E0 chapter 5.

9. Separate:
9crankcase
Refer to “CRANKCASE” in 1S7-F8197-E0
chapter 5.

10. Remove:
9guide stopper
9kickstarter shaft assembly

–22–
2S6-7-E0-01 05.11.18 1:14 PM Page 23

FRONT WHEEL AND BRAKE DISC CHAS

EASF0044

CHASSIS
FRONT WHEEL AND BRAKE DISC
1 Front wheel axle
2 Brake disc
3 Spacer
4 Oil seal
5 Bearing
6 Spacer
7 Speedometer gear unit

23 Nm (2.3 m•kg, 17 ft•lb )

1
3
4
5

LS

LS

6
5

40 Nm 4.0 m•kg, 28 ft•lb )

–23–
2S6-7-E0-01 05.11.18 1:14 PM Page 24

REAR WHEEL AND BRAKE CHAS

EASF0049

REAR WHEEL AND BRAKE

1 Collar 0 Cotter pin
2 Brake camshaft lever q Brake torque rod
3 Pin w Rear wheel drive hub damper
4 Drive chain puller (right) e Rear wheel drive hub
5 Brake shoe wear indicator r Drive chain puller (left)
6 Brake shoe plate t Rear wheel axle
7 Brake camshaft y Brake rod
8 Brake shoe
9 Rear wheel

7 Nm (0.7 m•kg, 5.0 ft•lb ) 3

2

5
t 4
LS

6 7
0
1 8
19 Nm (1.9 m•kg, 14 ft•lb )

q
0

16 Nm (1.6 m•kg, 12 ft•lb )

y

LS

9 7 Nm (0.7 m•kg, 5.0 ft•lb )

30 Nm (3.0 m•kg, 22 ft•lb )

LS

w
e r
LS

LS

60 Nm (6.0 m•kg, 43ft•lb )

–24–
2S6-7-E0-01 05.11.18 1:14 PM Page 25

HANDLEBAR CHAS
EASF0055

HANDLEBAR
1 Rear view mirror (left and 9 Throttle cable
right) 0 Handlebar bracket
2 Throttle grip q Brake lever
3 Throttle housing w Clutch lever
4 Master cylinder
5 Handlebar
6 Left handlebar switch
7 Handlebar grip
8 Starter cable

1
3

4 5
q

9
0

8
w

23 Nm (2.3 m•kg, 17 ft•lb )

53 Nm (5.3 m•kg, 39 ft•lb )

–25–
2S6-7-E0-01 05.11.18 1:14 PM Page 26

HANDLEBAR CHAS
EAS00666

REMOVING THE HANDLEBAR

1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there is
no danger of it falling over.

2. Remove:
9side cowlings (left and right)
9front cowling
9center panels
Refer to “REMOVING THE FRONT COWL-
INGS” in 1S7-F8197-E0 chapter 3.
9headlight assembly
Refer to “REPLACING THE HEADLIGHT
BULBS” in 1S7-F8197-E0 chapter 3.

3. Disconnect:
9meter assembly couplers 1
9right handlebar switch coupler 2
9left handlebar switch coupler 3
9front brake light switch connectors 4
3
4
1
2

4. Disconnect:
4 1
9clutch cable 1
9speedometer cable 2
9choke cable 3
5. Remove:
9speedometer assembly 4

2 3

6. Remove:
1 9rear view mirrors (left and right)
9brake master cylinder 1
9throttle housing

–26–
2S6-7-E0-01 05.11.18 1:14 PM Page 27

HANDLEBAR CHAS
7. Remove:
9lever holder (right) 1

8. Remove:
2 9throttle cable 1
9throttle grip 2

9. Remove:
9grip end 1

10. Remove:
9handlebar grip 1
9lever holder (left) 2
NOTE:
Blow compressed air between the handlebar and
the handlebar grip, and gradually push the grip
off the handlebar.

–27–
2S6-7-E0-01 05.11.18 1:14 PM Page 28

HANDLEBAR CHAS
11. Remove:
1
9relay 1
9wire harness strap 2

12. Remove:
1 9handlebar 1
9washers
9bushings
9handlebar bracket 2

EAS00670

INSTALLING THE HANDLEBAR

1. Stand the vehicle on a level surface.

w
Securely support the vehicle so that there is
no danger of it falling over.

2. Install:
9handlebar bracket 1
53 Nm (5.3 m•kg, 38 ft•lb)

1 b NOTE:
Align the projection a in the handlebar bracket
a with the slit b in the steering shaft.

–28–
2S6-7-E0-01 05.11.18 1:14 PM Page 29

HANDLEBAR CHAS
3. Install:
1 9bushings
9washers
9handlebar 23 Nm (2.3 m•kg, 17 ft•lb)
9wire harness strap
Refer to “CABLE ROUTING”.
4. Install:
9lever holder (left) 1
9handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.

w
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.

1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
9throttle grip 1
9throttle cable 2
9throttle housing
NOTE:
Lubricate the inside of the throttle grip with a thin
2
coat of lithium-soap-based grease and install it
onto the handlebar.

6. Install:
9lever holder (right) 1
NOTE:
Align the projection a on the right handlebar
1 switch with the hole in the handlebar.
a
w
Make sure the throttle grip operates smooth-
ly.

–29–
2S6-7-E0-01 05.11.18 1:14 PM Page 30

HANDLEBAR CHAS
7. Install:
9brake master cylinder
11 Nm (1.1 m·kg, 8.0 ft·lb)
Refer to “FRONT BRAKE” in 1S7-F8197-E0
chapter 7.
8. Install:
9plastic locking ties
Refer to “CABLE ROUTING”.
9. Adjust:
9throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in 1S7-F8197-E0
chapter 3.

Throttle cable free play (at the

flange of the throttle grip)
3–7 mm (0.12–0.28 in)

10. Adjust:
9clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY”.

Clutch cable free play (at the end

of the clutch lever)
8–12 mm (0.32–0.47 in)

–30–
2S6-F8197-E0_ cover 05.11.21 1:45 PM Page 2

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN